What is ISA-95?

2008-05-19 Copyright © 2008 BR&L Consulting 1

What is ISA-95?Industrial Best Practices of Manufacturing Information

Technologies with ISA-95 Models

Dennis Brandl, BR&L ConsultingIEC65E/JWG5 Convener

ISA 95 Editor

Copyright © 2008 BR&L Consulting 2

Dennis BrandlDennis Brandl

• Dennis Brandl has been an active member of ISA’s SP88 Batch Control System committee for the past seven years, a U.S. expert in batch control to IEC, editor of ISA’s SP95 Enterprise-Control System Integration standard, and convener of the IEC SC65E JWG 5 working group.

• He has been involved in automation system design and implementation for the past 30 years including Apollo and Space Shuttle test systems for Rockwell Space Division, as well as work with Shell Oil, Texas Instruments, Siemens, Square D, Sequencia, Telemecanique, and Modicon.

• Dennis has a B.S. in Physics, an M.S. in Measurement and Control from Carnegie Mellon University, and an M.S. in Computer Science from California State University.


What is ISA 95What is ISA 95

• A USA ANSI standard developed by an ISA Committee of volunteer experts

• ANSI/ISA 95.01-2000 “Enterprise - Control System Integration –Part 1: Models and Terminology”

• ANSI-ISA 95.02-2001 “Enterprise - Control System Integration –Part 2: Object Attributes”

• ANSI/ISA 95.03-2005 “Enterprise - Control System Integration –Part 3: Models of Manufacturing Operations”

• ANSI/ISA 95.05-2007 “Enterprise - Control System Integration –Part 5: Business to Manufacturing Transactions

• SP95 is the committee developing the ISA95 standards

• Also available as IEC/ISO 62264 standards


Why was ISA 95 DevelopedWhy was ISA 95 Developed

• Integration of business logistics systems to manufacturing systems is difficult and expensive

• Effective operation of manufacturing is difficult to explain and compare

• Integration of manufacturing operations systems is difficult and expensive

Material H

andling

Maintenance

Laboratories

Production

BusinessLogistics

ManufacturingOperations


Three Main AreaThree Main Area

• Models of exchanged information between business logistics systems and manufacturing operations systems► Part 1, 2, and 5

• Models of activities in manufacturing operations systems► Part 3

• Models of exchanged information within manufacturing operations systems► Future Part 4 and 6


BusinessLogistics


Why was ISA 95 Developed, Part 1,2,5Why was ISA 95 Developed, Part 1,2,5

• Integration of business logistics systems to manufacturing systems was difficult and expensive► Integration projects typically took one or

more years► Low success rate► Increasing use of ERP and need for

integration• Many reasons

► Different terminology and technical languages

► Different computer systems► Different organizational cultures ► ...


Why was ISA 95 Developed, Part 3 Why was ISA 95 Developed, Part 3

• Effective operation of manufacturing is difficult to explain and compare► Impossible to compare operations at

different plants and determine best practices► Difficult to explain end user requirements to

vendors, requirement projects took years► Difficult for vendors to explain solutions to

end users, sales took years► Difficult to compare MES solutions► MES (Manufacturing Execution Systems)

had no common definition► MES solutions were too related to

processing methods and too industry-specific

Material H

andling

Maintenance

Laboratories

Production



Why was ISA 95 Developed, Part 4, 6 Why was ISA 95 Developed, Part 4, 6

• Future Work for ISA SP95• Integration of production, maintenance,

laboratories, and material handling & storage is difficult

• Integration of manufacturing applications often takes 50% - 80% of a project cost► Many manufacturing sites have multiple

systems from multiple vendors and different release versions

• Part 4 will define commonly shared information between manufacturing activities

• Part 6 will define transactions on the information

Material H

andling

Maintenance

Laboratories

Production


BusinessLogistics


Integration of Business to Integration of Business to Manufacturing SystemsManufacturing Systems

ISA 95 Part 1, 2 and 5and

WBF B2MML Schemas


Typical Key Business DriversTypical Key Business Drivers

• Key Business Drivers► Key business drivers are the areas of performance that are most critical

to an organization's success • Available To Promise

► Requires detailed knowledge of available capacity• Reduced Cycle Time

► Major performance indicator with a direct impact on corporate profitability• Supply Chain Optimization

► Optimizing the manufacturing link in the supply chain – agile & responsive

• Asset Efficiency► Requires detailed knowledge of actual use

• Agile Manufacturing► Requires ability to quickly synchronize planning and production


ISA 95 Level DefinitionsISA 95 Level Definitions

• Level 0► Defines the actual physical processes.

• Level 1► Defines the activities involved in sensing and manipulating the physical

processes. • Level 2

► Defines the activities of monitoring and controlling the physical processes.

• Level 3► Defines the activities of the work flow to produce the desired end-

products. • Level 4

► Defines the business-related activities needed to manage a manufacturing organization.

• NOTE: There are other non manufacturing business-related activities that may be in Levels 1 through 4 or higher levels, but these are not defined in this standard, for example security activities.


ISA 95 LevelsISA 95 LevelsLevel 4

Level 1

Level 2

Level 3

Business Planning & Logistics

Plant Production Scheduling,Business Management, etc

Manufacturing Operations Management

Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...

Manufacturing ControlBasic Control, Supervisory Control,

Process Sensing, Process Manipulation,… 1 - Sensing the production process, manipulating the production process

2 - Monitoring, supervisory control and automated control of the production process

3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process.

Time FrameShifts, hours, minutes, seconds

4 - Establishing the basic plant schedule -production, material use, delivery, and shipping. Determining inventory levels.

Time FrameMonths, weeks, days, shifts

Level 0 0 - The physical production process


Level 4

Level 1

Level 2

Level 3

ISA 95 Corresponds to ApplicationsISA 95 Corresponds to Applications

1 - Sensing the production process, manipulating the production process

2 - Monitoring, supervisory control and automated control of the production process

3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process.

Time FrameShifts, hours, minutes, seconds

4 - Establishing the basic plant schedule -production, material use, delivery, and shipping. Determining inventory levels.

Time FrameMonths, weeks, days, shifts

Level 0 0 - The physical production process

ManufacturingOperations Systems

(MES, Batch, LIMS, AM, …)

Business LogisticsSystems

(ERP)

Control Systems(PLC, DCS, OCS, …)Intelligent devices

(Vision, Flow, …


Manufacturing Operations and ControlManufacturing Operations and Control

• A function is in the manufacturing and control domain if:

1. The function is critical to product quality2. The function is critical to plant safety3. The function is critical to plant reliability4. The function is critical to plant efficiency5. The function is critical to maintaining product or

production regulatory compliance• This includes such factors as safety, environmental, and

cGMP compliance (FDA, EPA, USDA, OSHA, …)

• Why ?► Answer - where is the responsibility.


Level 4Level 4--3 Exchanged Information3 Exchanged Information

Business InformationPlant Production Scheduling,Business Management, etc

Manufacturing Operationsand Control InformationArea Supervision, Production Planning,

Reliability, Assurance, etc

ProductionPerformance

What wasmade

and used

ProductionSchedule

What tomake

and use

ProductDefinition

How tomake

a product

ProductionCapability

What isavailable

to use

ResourceDefinitions

PersonnelEquipment

Material


ISA 95 Defines Formal Data ModelsISA 95 Defines Formal Data Models

• Data Models that represent exchanged information► Not an Enterprise Data Model► A way to represent information in a vendor independent method

• Defined in a UML notation► UML – Unified Modeling Language► ISO/IEC 19501-1, Information Technology—Unified Modeling

Language (UML)—Part 1: Specification

• Implemented using WBF’s B2MML schemas► XML Schema Definition (xsd)► xsd published as a W3C recommendation in May 2001


MaterialSublot

MaterialSublot

May be made upof sublots

0..n

0..n

0..n

MaterialDefinitionProperty

MaterialDefinitionProperty

Material LotProperty

Material LotProperty

QA TestSpecification

QA TestSpecification

MaterialDefinitionMaterial

Definition

Hasvalues for

0..n

0..n

0..n

0..n

0..n

Material LotMaterial Lot

QA TestResult

QA TestResult

1..1

0..n1..n

Hasproperties

of

Is testedby a

Maps to

Defined by

Records theexecution of

Made up of

MaterialClass

Property

MaterialClass

Property

MaterialClass

MaterialClass

0..n

Hasproperties

of

0..n

Definesa grouping

Is associatedwith a

Maymap to

Defines aprocedure forobtaining a

0..n

1..nIs testedby a

Material ModelMaterial Model

• Defines classes, material definitions, and instances• Defines properties and values• Defines QA Tests and results


<Material<MaterialLot>

<ID> W89W89 </ID><Description> A lot of materialA lot of material </Description><MaterialDefinitionID “WXE908WXE908”” /> /> <Location> Tank 1Tank 1 </Location><Quantity UnitOfMeasure = "KLKL" > 45004500</Quantity><MaterialLotProperty> <ID> dateTimeProductiondateTimeProduction </ID><Value> 20012001--0101--06T00:14:23+11:3006T00:14:23+11:30 </Value>

</MaterialLotProperty> <MaterialLotProperty><ID> Quality StatusQuality Status </ID><Value> GoodGood </Value>

</MaterialLotProperty></MaterialLot>

</Material>

A B2MML Example A B2MML Example –– Material LotMaterial Lot


A B2MML Example Production CapabilityA B2MML Example Production Capability

<ProductionCapability><ID>Area 54 : 2008Area 54 : 2008--0505--0101</ID><PublishedDate>20082008--0505--0101</PublishedDate><StartTime>8:00:008:00:00</StartTime><EndTime>16:00:0016:00:00</EndTime><EquipmentCapability><EquipmentID>”Production Line 2Production Line 2”</EquipmentID><CapabilityType>”AvailableAvailable”</CapabilityType><Reason>”Reduced rate due to maintenanceReduced rate due to maintenance”</Reason><Quantity><QuantityString>”200200”</QuantityString><DataType>”IntInt”</DataType><UnitOfMeasure>”Boards Per HourBoards Per Hour”</UnitOfMeasure>

</EquipmentCapability></ProductionCapability>


Information Receiver

Information Sender

CHANGE

RESPOND

Localprocessing

RESPOND SCHEDULEApplication Identification Area

Data Area

VERB = RESPOND

Noun = SCHEDULE…

CHANGE SCHEDULEApplication Identification Area

Data Area

VERB = CHANGE

Noun = SCHEDULEID= “A77818”Start Time = 2008-05-01 08:15:00….

Material ProducedID = 12345Quantity = 3000 Unit of Measure = 1 Liter Bottle

…

ISA 95 Part 5 ISA 95 Part 5 -- TransactionsTransactions


ISA 95 Part 1, 2, 6 BenefitsISA 95 Part 1, 2, 6 Benefits

• Benefits to End Users► Integration projects went from over one year to under

6 weeks► Success rate for projects went from less than 50% to

over 90% • Benefits to Vendors

► Integration costs reduced because of a standard format

► Less custom code to develop and support• Benefits to System Integrators

► Standard tools and methods can be applied ► More opportunities for integration projects


Compliance with ISA 95 and B2MMLCompliance with ISA 95 and B2MML

• A New Organization is starting to test compliance with B2MML messages

• Setup as an independent compliance test lab

• Will start certification processes in early 2009

Industrial InteroperabilityCompliance Institute

(a forum in ASCI)


Material H

andling

Maintenance

Laboratories

Production


Models ofModels ofManufacturing OperationsManufacturing Operations

ISA 95 Part 3


ISA 95 ISA 95 –– Requirements for MOMRequirements for MOM

• The ISA 95 Part 3 standard defines the activities that occur in Manufacturing Operations Management (MOM)► Production Operations Management► Maintenance Operations Management► Laboratory (Quality) Operations Management► Material Handling & Storage (Inventory) Operations Management► Supporting activities

• Management of security• Management of information• Management of configuration• Management of documents• Management of regulatory compliance• Management of incidents and deviations

• Tasks and activities are used as a map to identify MOM requirements


ResourceinformationResourceResource

informationinformation

The Production Elements of ISA 95The Production Elements of ISA 95

Productiondata

collection

Productionexecution

management

Productionresource

management

Productiondispatching

Productiontracking

ProductionperformanceProductionProduction

performanceperformance

Detailedproductionscheduling

Productionschedule

ProductionProductionscheduleschedule

Productdefinition

management

Level 1-2 Functions

ProductionPerformance

analysis

Productioncapability

ProductionProductioncapabilitycapability

ProductdefinitionProductProduct

definitiondefinition

Equipment and processspecific production rules

Equipment and processspecific data

Operationalresponses

Operationalcommands


Activities andActivities andTasksTasks

• Part 3 lists tasks that occur in each activity

• It does not specify an architecture or organization

• Task list can be quickly converted into requirements

• Users identify which activities are to be supported

• Users identify which resources (equipment, personnel, material) are to be supported

• Users write requirements using ISA 95 terminology


A Template for MES RequirementsA Template for MES Requirements

• Typical end user requirements document

• Used to comparedifferent vendor’s functionality and capabilities

• We finally have a vendor independent description of MES

• We finally have a common way to compare different facilities


Benefits of ISA 95 Part 3Benefits of ISA 95 Part 3

• Benefits to End Users► Significant reduction in time to determine MES

requirements► Project time reduced from months to weeks► Possible to compare different vendor solutions► Possible to compare different facilities

• Benefits to Vendors► Standard language to use with customers► Quickly demonstrate functions and problems solved

• Benefits to System Integrators► Many more MOM projects► Many more opportunities for integration projects


The FutureThe FutureObject Models for Manufacturing Object Models for Manufacturing

to Manufacturing Integrationto Manufacturing Integration

Plans for Part 4 and Part 6

Material H

andling

Maintenance

Laboratories

Production


Maintenance ResponseMaintenance Request

Equipment and processspecific production rules

Datacollection

Executionmanagement

Resourcemanagement

Dispatching

Tracking

Detailedscheduling

Definitionmanagement

Operations level 1-2 functions

Analysis

Equipment and processspecific data

Operationalresponses

Operationalcommands

WorkSchedule

Master WorkDefinition

Master Recipeetc …

Work Dispatch List

Control Recipeetc…

Control WorkDefinition

Work ProductionRecord

Batch ProductionRecord, etc …

PersonnelMaterial

Equipment

Work KPI

Work ProcessSegment

Batch List, etc…

Physical Asset

Defined in other standardsDefined in Part 4Defined in Part 2

Legend

Production performanceProduction scheduleProduction capabilityProduct definition

Work PerformanceWork Capability

Process Segment

From ISA 95 Part 2 WD04


SummarySummary

• The ISA 95 has been a major success► Reducing ERP-MES/MOM integration efforts by over

90%► Improving integration project success from under 50%

to over 90%► Reducing early phases of MES/MOM projects by over

75%► Helping revitalize the MES/MOM marketplace► Increasing MES/MOM competition► Helping improve manufacturing productivity► Work done by volunteers


Thank youThank you

Dennis Brandl

Documents

What is ISA-95?